### Commercial **Airplanes** 

# 747 Service Bulletin **SPECIAL ATTENTION Number: 747-53-2460**  Original Issue: June 27, 2002 Revision 2: December 22, 2010 ATA System: 5312 **SUBJECT:**FUSELAGE - Number 3 Main Entry Door - Lower Forward Corner Reveal - Inspection and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 1 of 106 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 2 of 106 **BOEING SERVICE BULLETIN 747-53-2460**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 35 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 36 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1. Kits/Parts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 41 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 42 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 1: LOGIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION. . . . . . 48 FIGURE 3: DOOR CORNER REVEAL - INSPECTION FOR CRACKS. . . . . . . . . . . . . . . . . 55 FIGURE 4: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION. . . . . . . . . . . . . . . . 57 FIGURE 5:ACCESS AND RESTORATION FOR DOOR CORNER REVEAL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT. . . . . . . . . . . . . . . . . 61 FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR . . . 70 FIGURE 8: DOOR CORNER REVEAL - WELD REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . 78 FIGURE 9: DOOR CORNER REVEAL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . 83

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 3 of 106 **BOEING SERVICE BULLETIN 747-53-2460**FIGURE 11: INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL . 92 FIGURE 12: REMOVAL OF THE SHARP EDGE DETAIL FROM THE DOOR CORNER REVEAL . . . 95 FIGURE 13: REWORK OF A 1-PIECE LEFT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR CORNER REVEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 FIGURE 14: REWORK OF A 1-PIECE RIGHT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR CORNER REVEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 FIGURE 15: LOGIC DIAGRAM FOR THE INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 FIGURE 16: LOGIC DIAGRAM FOR THE INSPECTION OF MACHINED REVEALS WITH SHARP EDGE DETAIL REMOVED FOR CRACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 FIGURE 17: INSPECTION FOR ONE OR TWO-PIECE CORNER REVEALS. . . . . . . . . . . . . 103 Appendix A: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION PROCEDURE. . . . . . . 105

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 4 of 106 **BOEING SERVICE BULLETIN 747-53-2460**

### Commercial **Airplanes** 

# 747 Service Bulletin **SPECIAL ATTENTION Revision Transmittal Sheet**  **Number: 747-53-2460** Original Issue: June 27, 2002 Revision 2: December 22, 2010 ATA System: 5312 **SUBJECT:**FUSELAGE - Number 3 Main Entry Door - Lower Forward Corner Reveal - Inspection and Replacement This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** More work is necessary on airplanes line number 1038 - 1270 (new Group 4 airplanes) with corner reveals that were: 1. Changed by rework of existing one-piece corner reveals into two-piece corner reveals in accordance with Revision 1 of this service bulletin. On these airplanes, it is necessary to do a material type inspection to determine if any reworked corner reveals are made from cast aluminum. Any reworked cast aluminum corner reveals must be replaced with machined aluminum two-piece corner reveals or inspected periodically. 2. Inspected in accordance with Revision 1 of this service bulletin, but not replaced. On these airplanes, the repeat inspection interval has been reduced, and at the next inspection for cracks also do a material type inspection to determine if the reveals are made from cast aluminum. Cast aluminum corner reveals have a shorter repeat inspection interval than machined aluminum corner reveals. Continue to do repeat inspections in accordance with Revision 2 of this service bulletin on any airplane with door 3 lower forward corner reveals that were previously inspected in accordance with Revision 1 of this service bulletin, but not replaced, or that were replaced with new or repaired one-piece corner reveals. No more work is necessary on any affected airplane on which one-piece corner reveals were replaced with new machined aluminum two-piece corner reveals in accordance with Revision 1 of this service bulletin. No airplanes were added to this service bulletin effectivity. However, based on an in-service report, airplanes line number 1038 - 1270 were moved from Group 2 to new Group 4. Group 4 airplanes may have been delivered with either cast aluminum or machined aluminum one-piece door 3 lower forward corner reveals. In addition, airplanes that have been modified to the Boeing Converted Freighter (BCF) or the Large Cargo Freighter (LCF) configuration have been removed from the service bulletin effectivity. Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-18-07, is related to this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 5 of 106**REASON FOR REVISION** This revision is sent to include the changes that follow: 1. The Work Instructions in Paragraph 3.B. have been rewritten to make it more clear that the material type inspection is only applicable to Group 1 and 4 airplanes, under certain conditions. The material type inspection is necessary to identify castings if the operator wants to attempt to repair cracked one-piece lower forward corner reveals by welding. The material type inspection is also necessary to identify castings if the operator wants to rework uncracked one-piece reveals into two-piece reveals. Only machined aluminum reveals can be reworked, cast aluminum reveals cannot be reworked. 2. New Part 6 has been added to Paragraph 3.B to show the additional work that is necessary on Group 4 airplanes on which uncracked one-piece corner reveals were reworked into two-piece corner reveals and installed in accordance with Revision 1 of this service bulletin. As a result of the new in-service report noted earlier, it is possible that Group 4 airplanes were delivered with cast aluminum corner reveals. Revision 1 of this service bulletin did not require a material type inspection on Group 4 airplanes to verify that any one-piece corner reveal was not an aluminum casting prior to rework into a two-piece corner reveal. 3. The logic diagrams in FIGURE 1, FIGURE 15, and FIGURE 16 have been removed. The data previously in those logic diagrams is included in the tables in Paragraph 1.E., Compliance. 4. Paragraph 1.E., Compliance and Paragraph 3.B., Work Instructions have been changed to allow operators the option to replace a corner reveal prior to accomplishing any inspections of that reveal. 5. The Background and Action sections on the Summary page, Paragraph 1.C., Reason, and Paragraph 1.D., Description have been updated to agree with the new Work Instructions in Paragraph 3.B., and the service history has been updated. 6. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, and in Figure 2, references to Parting Agent G00771 have been replaced with Parting Agent AC962-73C. Parting agent G00771 is no longer available. In Figure 10, an optional nut part number has been identified. 7. References to FAA Airworthiness Directive AD 2008-18-07 have been added. References to AD 96-23-05 were changed to AD 2007-12-11, which has superseded AD 96-23-05. 8. The data given in Information Notice 747-53-2460 IN 01 is included in this revision. IN 01 made general clarifications to the instructions in Paragraph 3.B., Work Instructions. Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** June 27, 2002 Original Issue: February 13, 2007 Revision 1: December 22, 2010 Revision 2:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 6 of 106 **BOEING SERVICE BULLETIN 747-53-2460**

### Commercial **Airplanes** 

# 747 Service Bulletin **SPECIAL ATTENTION Summary**  **Number: 747-53-2460** Original Issue: June 27, 2002 Revision 2: December 22, 2010 ATA System: 5312 **SUBJECT:**FUSELAGE - Number 3 Main Entry Door - Lower Forward Corner Reveal - Inspection and Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS** Refer to Paragraph 1.B., Concurrent Requirements. **BACKGROUND** Accomplishment of the inspection, repair, rework, or replacement of the Door 3 Lower Forward Corner Reveals shown in this service bulletin will ensure the structural integrity of the attachment of the forward girt bar fitting for the Door 3 escape slide. Failure of the Corner Reveal could cause the girt bar fitting to have misalignment from the airplane structure. Girt bar misalignment from airplane structure would allow the door escape slide to depart from the airplane if the slide was deployed for an evacuation resulting in injury to passengers and crew using the escape slide. The Door 3 Lower Forward Corner Reveals are either a casting that is made from 356 aluminum or a machined part that is made from 6061 aluminum. The cast Corner Reveals have been found to crack while, prior to the initial release of this service bulletin, there have been no reports of the machined Corner Reveals cracking. Most of the airplanes in Group 1 of this service bulletin were delivered with the cast Corner Reveal, however, some Group 1 airplanes had an option for the corner reveal to be machined from 6061 aluminum plate. Deflection of the airplane structure at the door 3 frame causes the door corner reveal to crack. Prior to the initial release of this service bulletin, seven operators have made a report of eleven cracked Door 3 Forward Corner Reveals. All eleven Corner Reveals were castings that were made from the 356 aluminum. Since the initial release of this service bulletin, an operator has reported a cracked, machined 6061 aluminum corner reveal. As a result of this report, airplanes line number 1038 through 1381, which were delivered with machined 6061 aluminum corner reveals, were added to this service bulletin as Groups 2 and 3. In addition, it has been found that airplanes line number 1038 through 1342 (Group 2 airplanes) may have been delivered with a "sharp edge" detail on the outboard side of the reveal. This sharp edge detail can lead to reveal cracks. Airplanes line number 1343 through 1381 (Group 3 airplanes) were reworked during production to remove the sharp edge detail.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 7 of 106Since the release of Revision 1 of this service bulletin, an operator has reported that a cracked cast aluminum corner reveal was found on a Group 2 airplane, as defined in Revision 1 of this service bulletin. Boeing data had indicated that those airplanes had all been delivered with machined aluminum corner reveals. Based on that report, airplanes line number 1038 through 1270 were moved from Group 2 to Group 4. The escape slide at Door 3 provides for a means of rapid egress from the airplane during an emergency evacuation. In the automatic mode, girt bar locks at Door 3 are secured to the doorway sill by girt bar floor fittings. When the Door 3 is opened, the escape slide is automatically deployed while secured to floor fittings. If a floor fitting becomes misaligned due to a cracked Corner Reveal, the escape slide can become detached from the airplane. This service bulletin addresses cracking of the Corner Reveal located in the lower forward corner of the Main Entry Door Number 3. Airplanes in Group 1 of this service bulletin were delivered with the Corner Reveal made from a casting. After line number 1270, The subject part has been made from 6061aluminum plate. The subject part is shown in Figure 3 identified as a Corner Reveal. In Service Bulletin 747-53A2378 the same part has been identified as a Corner Casting or Support Fitting. AD 2007-12-11 identifies this part as a Corner Casting. This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original release and Revision 1 of service bulletin 747-53A2378 for airplanes line number 1 through 868. Boeing Service Related Problem (SRP)s 747-SRP-53-0129 and 747-SRP-53-0232 are related to this service bulletin. Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin 747-53A2378. **ACTION (PRR 85901-60RS)** Get access to the Door 3 lower forward corner reveal as shown in this service bulletin. Do a general visual inspection of the installed lower forward corner reveals for one-piece or two-piece reveals. Also do an inspection to determine the material type. No more work is necessary at any two-piece corner reveals that are found that are not castings. On Group 1, Configuration 1, Group 2 and Group 4 airplanes with affected corner reveals that are not castings, do a detailed inspection of any installed one-piece corner reveal for a sharp edge detail. If a sharp edge detail is found, rework the reveal to remove the sharp edge in accordance with this service bulletin. After rework, or if no sharp edge detail is found, do a detailed inspection of the reveal for cracks. On Group 1, Configuration 1 and Group 3 airplanes, do a detailed inspection of any installed one-piece reveal for cracks. If any crack is found, replace the reveal with a two-piece reveal. No more work is necessary after installation of the two-piece reveal. As an alternative to replacement, cracked cast aluminum reveals (installed as an option on Group 1 and 4 airplanes only) can be repaired by welding in accordance with this service bulletin. Continue to do inspections of reveals that have been repaired until replaced with two-piece reveals. If no cracks are found, continue to do inspections in accordance with this service bulletin until replaced with a two-piece reveal. As an alternative to repeated inspections, one-piece reveals can be replaced with two-piece reveals. No more work is required after installation of two-piece reveals.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 8 of 106 **BOEING SERVICE BULLETIN 747-53-2460 EFFECTIVITY**  747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D and 747SR airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-18-07 and AD 2007-12-11 are related to this service bulletin. Boeing recommends that inspections, repair, rework, or replacement of the Door 3 Forward Corner Reveal be accomplished in accordance with the tables in Paragraph 1.E., Compliance . This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original release and Revision 1 of Service Bulletin 747-53A2378 for airplanes line number 1 through 868. Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin 747-53A2378. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspections and repair procedures given in this service bulletin. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 9 of 106 **BOEING SERVICE BULLETIN 747-53-2460**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 10 of 106 **BOEING SERVICE BULLETIN 747-53-2460**

### Commercial **Airplanes** 

# 747 Service Bulletin **SPECIAL ATTENTION Number: 747-53-2460**  Original Issue: June 27, 2002 Revision 2: December 22, 2010 ATA System: 5312 **SUBJECT:**FUSELAGE - Number 3 Main Entry Door - Lower Forward Corner Reveal - Inspection and Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 85901-009SK and PRR 85901-60RS for data about this change. **NOTE:**This service bulletin is not applicable if Door 3 has been deactivated. However, if Door 3 has been deactivated and then reactivated, this service bulletin is applicable.
**DESCRIPTION CONFIGURATION**  **GROUP** 747 airplanes line number 1 through 1037, except 747SP, 747-200F, and 747-400F airplanes, and airplanes modified by Boeing to the Special Freighter, Boeing Converted Freighter, or Large Cargo Freighter configuration. - 1

With the Door 3 lower corner reveal not previously replaced in accordance with the original issue of this service bulletin. 1
With the Door 3 lower corner reveal previously replaced in accordance with the original issue of this service bulletin. 2
747 airplanes line number 1272 - 1342, except 747-400F airplanes and airplanes modified by Boeing to the Boeing Converted Freighter or Large Cargo Freighter configuration. - 2

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 11 of 106**DESCRIPTION CONFIGURATION**  **GROUP** 747 airplanes line number 1343 - 1381, except 747-400F airplanes and airplanes modified by Boeing to the Boeing Converted Freighter or Large Cargo Freighter configuration. - 3

747 airplanes line number 1038 -1270, except 747SP, 747-200F, and 747-400F airplanes and airplanes modified by Boeing to the Boeing Converted Freighter or Large Cargo Freighter configuration. - 4

Airplane Models: 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D, 747SR **Group Variable Number** 1 RA001 - RA025 1 RA027 - RA028 1 RA030 - RA032 1 RA034 1 RA104 - RA110 1 RA113 - RA115 1 RA164 1 RA201 - RA203 1 RA216 - RA217 1 RA245 - RA246 1 RA251 - RA266 1 RA301 - RA318 1 RA351 - RA360 1 RA369 - RA373 1 RA401 - RA418 1 RA501 - RA502 1 RA521 - RA523 1 RA525 - RA528 1 RA532 - RA548 1 RA551 - RA552 1 RA559 - RA561 1 RA581 - RA582

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 12 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group**  **Variable Number**1 RA585 1 RA601 - RA602 1 RA631 1 RA633 1 RA651 - RA652 1 RA671 - RA677 1 RA701 - RA702 1 RA721 - RA731 1 RA741 - RA745 1 RA749 - RA750 1 RA761 - RA762 1 RA781 - RA784 1 RA903 - RA909 1 RB001 - RB016 1 RB042 1 RB044 1 RB071 - RB075 1 RB101 - RB102 1 RB411 - RB413 1 RB421 1 RB601 - RB603 1 RB681 - RB695 1 RB697 1 RB711 1 RB721 - RB723 1 RB741 - RB748 1 RD001 - RD004 1 RD021 - RD022 1 RD042 1 RD045 - RD054 1 RD056 - RD059 1 RD071 - RD072 1 RD081

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 13 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group**  **Variable Number**1 RD091 - RD092 1 RD101 - RD104 1 RD121 - RD127 1 RD131 - RD141 1 RD143 1 RD166 - RD167 1 RD171 - RD172 1 RD181 - RD183 1 RD201 - RD204 1 RD221 - RD224 1 RD226 1 RD231 - RD232 1 RD241 - RD243 1 RD251 - RD262 1 RD271 - RD272 1 RD291 - RD292 1 RD311 1 RD351 - RD357 1 RD381 - RD383 1 RD413 - RD414 1 RD421 - RD426 1 RD431 - RD435 1 RD451 - RD456 1 RD471 - RD475 1 RD513 - RD519 1 RD531 - RD533 1 RD561 1 RD571 1 RD591 - RD593 1 RD603 - RD607 1 RD621 1 RD644 - RD645 1 RD647 - RD649

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 14 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group**  **Variable Number**1 RD651 - RD659 1 RD661 1 RD671 1 RD681 - RD682 1 RD692 1 RD701 - RD702 1 RD721 - RD722 1 RD741 - RD742 1 RD751 1 RD753 - RD755 1 RD761 1 RD771 - RD775 1 RD781 - RD783 1 RD791 - RD792 1 RE001 2 RF001 - RF006 1 RJ131 - RJ133 1 RJ151 - RJ152 1 RJ301 - RJ303 1 RJ321 - RJ322 1 RJ331 - RJ333 4 RM001 - RM005 2 RM006 - RM0072 RM010 4 RM011 - RM012 2 RM013 4 RM021 - RM0244 RM026 - RM0272 RM028 - RM0304 RM036 - RM039 2 RM040 4 RM041 - RM0432 RM044 - RM045

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 15 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group**  **Variable Number**4 RM051 2 RM052 - RM0534 RM071 4 RM081 - RM0844 RM091 4 RM096 - RM0974 RM116 - RM1174 RM126 - RM1274 RM129 - RM131 2 RM132 4 RM136 - RM1474 RM156 - RM158 4 RM166 - RM1774 RM191 - RM192 4 RM231 - RM2334 RM241 - RM2442 RM245 - RM2464 RM261 - RM2644 RM316 - RM318 4 RM331 - RM3334 RM341 4 RM351 2 RM352 - RM355 2 RM366 - RM3672 RM401 - RM402 3 RM403 2 RM426 2 RM431 3 RM441 - RM443 3 RM445 4 RM801 - RM802 2 RM803 4 RM811 - RM813

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 16 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group**  **Variable Number**1 RS001 - RS002 1 RS201 1 RS211 - RS212 1 RS221 - RS222 1 RS231 - RS241 1 RS251 - RS259 1 RS263 1 RS265 - RS268 1 RS271 - RS276 1 RS291 - RS292 1 RS301 - RS306 1 RS311 - RS320 1 RS331 - RS333 1 RS341 - RS342 1 RS699 1 RS701 - RS703 1 RS711 - RS713 1 RS731 - RS732 1 RS742 1 RS751 - RS752 1 RS761 1 RS781 - RS782 1 RT001 - RT011 4 RT012 - RT014 4 RT034 - RT035 1 RT041 - RT047 1 RT061 1 RT073 - RT074 1 RT101 - RT103 1 RT121 1 RT131 - RT134 4 RT135 - RT137 4 RT151 - RT152

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 17 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group**  **Variable Number**1 RT162 - RT163 4 RT165 - RT168 1 RT401 - RT412 1 RT431 - RT441 4 RT442 - RT447 1 RT451 - RT455 1 RT457 - RT460 1 RT462 - RT468 4 RT469 1 RT471 - RT498 4 RT499 1 RT502 - RT505 1 RT511 - RT512 1 RT514 - RT515 1 RT517 1 RT521 - RT523 1 RT525 4 RT526 - RT527 4 RT529 - RT530 1 RT531 - RT535 1 RT551 - RT568 1 RT571 1 RT580 - RT584 4 RT585 - RT590 1 RT591 1 RT601 - RT622 4 RT623 - RT630 1 RT633 - RT635 4 RT636 - RT640 1 RT641 1 RT643 - RT654 1 RT671 - RT673 1 RT681 - RT682

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 18 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group**  **Variable Number**1 RT691 - RT697 4 RT698 - RT699 1 RT701 - RT704 1 RT711 - RT717 1 RT741 - RT742 1 RT744 - RT749 4 RT750 1 RT753 - RT755 4 RT756 - RT757 1 RT776 - RT777 1 RT783 - RT784 4 RT801 - RT803 4 RT811 - RT814 4 RT831 - RT836 1 RT861 - RT864 1 RT877 - RT879 4 RT880 1 RT931 - RT932 1 RT945 4 RT946 - RT949 1 RT951 - RT954 4 RT955 1 RT966 1 RU001 - RU004 4 RU005 - RU006 4 RU016 - RU017 1 RU031 - RU032 1 RU051 - RU052 4 RU059 - RU060 1 RU061 - RU062 1 RU081 - RU082 4 RU083 4 RU101 - RU102

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 19 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group**  **Variable Number**4 RU121 - RU132 1 RU801 - RU809 1 RU831 - RU839 4 RU840 - RU841 2. Spares Affected None. **B. Concurrent Requirements** The service bulletin listed below can be done before or at the same time as this service bulletin: **Description Service Bulletin**  **Company** Service Bulletin 747-53A2378 accomplishes an inspection of the support structure under the Corner Reveal for corrosion. (a) (b) 747-53A2378 Revision 2, Revision 3, or Revision 4 Boeing

(a) At Door 3 only, for airplanes with common effectivity. (b) Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin 747-53A2378.
**C. Reason** Accomplishment of the inspection, repair, rework, or replacement of the Door 3 Lower Forward Corner Reveals shown in this service bulletin will ensure the structural integrity of the attachment of the forward girt bar fitting for the Door 3 escape slide. Failure of the Corner Reveal could cause the girt bar fitting to have misalignment from the airplane structure. Girt bar misalignment from airplane structure would allow the door escape slide to depart from the airplane if the slide was deployed for an evacuation resulting in injury to passengers and crew using the escape slide. The Door 3 Lower Forward Corner Reveals are either a casting that is made from 356 aluminum or a machined part that is made from 6061 aluminum. The cast Corner Reveals have been found to crack while, prior to the initial release of this service bulletin, there have been no reports of the machined Corner Reveals cracking. Most of the airplanes in Group 1 of this service bulletin were delivered with the cast Corner Reveal, however, some Group 1 airplanes had an option for the corner reveal to be machined from 6061 aluminum plate. Deflection of the airplane structure at the door 3 frame causes the door corner reveal to crack. Prior to the initial release of this service bulletin, seven operators have made a report of eleven cracked Door 3 Forward Corner Reveals. All eleven Corner Reveals were castings that were made from the 356 aluminum.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 20 of 106 **BOEING SERVICE BULLETIN 747-53-2460**Since the initial release of this service bulletin, an operator has reported a cracked, machined 6061 aluminum corner reveal. As a result of this report, airplanes line number 1038 through 1381, which were delivered with machined 6061 aluminum corner reveals, were added to this service bulletin as Groups 2 and 3. In addition, it has been found that airplanes line number 1038 through 1342 (Group 2 airplanes) may have been delivered with a "sharp edge" detail on the outboard side of the reveal. This sharp edge detail can lead to reveal cracks. Airplanes line number 1343 through 1381 (Group 3 airplanes) were reworked during production to remove the sharp edge detail. Since the release of Revision 1 of this service bulletin, an operator has reported that a cracked cast aluminum corner reveal was found on a Group 2 airplane, as defined in Revision 1 of this service bulletin. Boeing data had indicated that those airplanes had all been delivered with machined aluminum corner reveals. Based on that report, airplanes line number 1038 through 1270 were moved from Group 2 to Group 4. The escape slide at Door 3 provides for a means of rapid egress from the airplane during an emergency evacuation. In the automatic mode, girt bar locks at Door 3 are secured to the doorway sill by girt bar floor fittings. When the Door 3 is opened, the escape slide is automatically deployed while secured to floor fittings. If a floor fitting becomes misaligned due to a cracked Corner Reveal, the escape slide can become detached from the airplane. This service bulletin address cracking of the Corner Reveal located in the lower forward corner of the Main Entry Door Number 3. The airplanes in Group 1 of this service bulletin were delivered with the cast Corner Reveal. After line number 1270, the subject part has been made from 6061 aluminum plate. The subject part is shown in Figure 3 identified as a Corner Reveal. In Service Bulletin 747-53A2378 the same part has been identified as a Corner Casting or Support Fitting. AD 2007-12-11 identifies this part as a Corner Casting. This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original release and Revision 1 of Service Bulletin 747-53A2378 for airplanes line number 1 through 868. Boeing Service Related Problem (SRP)s 747-SRP-53-0129 and 747-SRP-53-0232 are related to this service bulletin. Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin 747-53A2378. Revision 1 is sent to add inspection and modification of one-piece Door 3 lower forward corner reveals that are machined from 6061 aluminum. Installation of machined aluminum corner reveals had been considered terminating action for the inspections in this service bulletin, but since the initial release of this service bulletin, Boeing has received a report of a cracked machined aluminum corner reveal. Replacement of the one-piece machined aluminum corner reveals with two-piece machined aluminum corner reveals is now considered terminating action. The machined 6061 aluminum one-piece corner reveals were delivered on airplanes line number 1038 through 1381. In addition, airplanes line number 1038 - 1342 and those airplanes previously modified as shown in this service bulletin may have corner reveals installed that have a "sharp edge" detail at the forward edge. This sharp edge can lead to cracks. On these airplanes, an inspection is included to find and remove the sharp edge. The Accomplishment Instructions have been rewritten, and Figures 9 through 16 have been added to show the new inspections, modifications, and corner reveal replacement instructions. Revision 1 also clarifies Views A and View B in Figures 6 and 7. The change to Views A and B show that the two fasteners, identified by fastener code "B," are installed under the serrated plate and not through the serrated plate.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 21 of 106 **BOEING SERVICE BULLETIN 747-53-2460**Part quantities are clarified in Figure 6, Circle Notes 28 and 29, and in Figure 7, Circle Notes 16 and 17. Clarified the nutplate locations in Figure 7, View C illustration. Revision 1 also adds the G00771 bulk consumable material to the Paragraph 2.C.2. "Parts and Materials Supplied by the Operator." References to FAA Notice of Proposed Rulemaking (NPRM), FAA Docket Number 2002-NM-285-AD, have been added. Revision 2 includes these changes: 1. The Work Instructions in Paragraph 3.B. have been rewritten to make it more clear that the material type inspection is only applicable to Group 1 and 4 airplanes, under certain conditions. The material type inspection is necessary to identify castings if the operator wants to attempt to repair cracked one-piece lower forward corner reveals by welding. The material type inspection is also necessary to identify castings if the operator wants to rework uncracked one-piece reveals into two-piece reveals. Only machined aluminum reveals can be reworked, cast aluminum reveals cannot be reworked. 2. New Part 6 has been added to Paragraph 3.B to show the additional work that is necessary on Group 4 airplanes on which uncracked one-piece corner reveals were reworked into two-piece corner reveals and installed in accordance with Revision 1 of this service bulletin. As a result of the new in-service report noted earlier, it is possible that Group 4 airplanes were delivered with cast aluminum corner reveals. Revision 1 of this service bulletin did not require a material type inspection on Group 4 airplanes to verify that any one-piece corner reveal was not an aluminum casting prior to rework into a two-piece corner reveal. 3. The logic diagrams in FIGURE 1, FIGURE 15, and FIGURE 16 have been removed. The data previously in those logic diagrams is included in the tables in Paragraph 1.E., Compliance. 4. Paragraph 1.E., Compliance and Paragraph 3.B., Work Instructions have been changed to allow operators the option to replace a corner reveal prior to accomplishing any inspections of that reveal. 5. The Background and Action sections on the Summary page, Paragraph 1.C., Reason, and Paragraph 1.D., Description have been updated to agree with the new Work Instructions in Paragraph 3.B., and the service history has been updated. 6. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, and in Figure 2, references to Parting Agent G00771 have been replaced with Parting Agent AC962-73C. Parting agent G00771 is no longer available. In Figure 10, an optional nut part number has been identified. 7. References to FAA Airworthiness Directive AD 2008-18-07 have been added. References to AD 96-23-05 were changed to AD 2007-12-11, which has superseded AD 96-23-05. 8. The data given in Information Notice 747-53-2460 IN 01 is included in this revision. IN 01 made general clarifications to the instructions in Paragraph 3.B., Work Instructions. **D. Description** Get access to the Door 3 lower forward corner reveal as shown in this service bulletin. Do a general visual inspection of the installed lower forward corner reveals for one-piece or two-piece reveals. Also do an inspection to determine the material type. No more work is necessary at any two-piece corner reveals that are found that are not castings.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 22 of 106 **BOEING SERVICE BULLETIN 747-53-2460**On Group 1, Configuration 1, Group 2 and Group 4 airplanes with affected corner reveals that are not castings, do a detailed inspection of any installed one-piece corner reveal for a sharp edge detail. If a sharp edge detail is found, rework the reveal to remove the sharp edge in accordance with this service bulletin. After rework, or if no sharp edge detail is found, do a detailed inspection of the reveal for cracks. On Group 1, Configuration 1 and Group 3 airplanes, do a detailed inspection of any installed one-piece reveal for cracks. If any crack is found, replace the reveal with a two-piece reveal. No more work is necessary after installation of the two-piece reveal. As an alternative to replacement, cracked cast aluminum reveals (installed as an option on Group 1 and 4 airplanes only) can be repaired by welding in accordance with this service bulletin. Continue to do inspections of reveals that have been repaired until replaced with two-piece reveals. If no cracks are found, continue to do inspections in accordance with this service bulletin until replaced with a two-piece reveal. As an alternative to repeated inspections, one-piece reveals can be replaced with two-piece reveals. No more work is required after installation of two-piece reveals. This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original release and Revision 1 of Service Bulletin 747-53A2378 for airplanes line number 1 through 868. Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin 747-53A2378. Revision 1 - More work is necessary on airplanes changed as shown in the initial release of this service bulletin. If the corner reveal was replaced as shown in the initial release of this service bulletin, do more inspections for cracks or a sharp edge detail as shown in this revision. If no cracks are found, continue to do inspections, rework or replace the corner reveal as shown in this revision. If a sharp edge detail is found, rework or replace the corner reveal as shown in this revision. Continue to do inspections as shown in this revision until the one-piece corner reveal is replaced with a two-piece corner reveal. Revision 2 - More work is necessary on airplanes line number 1038 - 1270 (new Group 4 airplanes) with corner reveals that were: 1. Changed by rework of existing one-piece corner reveals into two-piece corner reveals in accordance with Revision 1 of this service bulletin. On these airplanes, it is necessary to do a material type inspection to determine if any reworked corner reveals are made from cast aluminum. Any reworked cast aluminum corner reveals must be replaced with machined aluminum two-piece corner reveals or inspected periodically. 2. Inspected in accordance with Revision 1 of this service bulletin, but not replaced. On these airplanes, the repeat inspection interval has been reduced, and at the next inspection for cracks also do a material type inspection to determine if the reveals are made from cast aluminum. Cast aluminum corner reveals have a shorter repeat inspection interval than machined aluminum corner reveals. Continue to do repeat inspections in accordance with Revision 2 of this service bulletin on any airplane with door 3 lower forward corner reveals that were previously inspected in accordance with Revision 1 of this service bulletin, but not replaced, or that were replaced with new or repaired one-piece corner reveals. No more work is necessary on any affected airplane on which one-piece corner reveals were replaced with new machined aluminum two-piece corner reveals in accordance with Revision 1 of this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 23 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1:**
**Affected Maintenance Zones Zone**  **Model** 241, 242 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D, 747SR **Group 2-3:**
**Affected Maintenance Zones Zone**  **Model** 241, 242 747-400 **Group 4:**
**Affected Maintenance Zones Zone**  **Model** 241, 242 747-400, 747-400D **E. Compliance** Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-18-07 and AD 2007-12-11 are related to this service bulletin. This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original release and Revision 1 of Service Bulletin 747-53A2378 for airplanes line number 1 through 868. Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin 747-53A2378 . **Previously Inspected or Changed in Accordance With Revision 1 of this**  **Service Bulletin Not Previously Inspected or Changed**  **in Accordance With Revision 1 of this Service Bulletin**  **Airplane Group**

Use Table 5 Use Table 2 Group 1, Configuration 1 Use Table 6 Use Table 3 Group 1, Configuration 2 Use Table 6 Use Table 3 Group 2 Use Table 4 Use Table 4 Group 3 Use Table 1 Use Table 2 Group 4

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 24 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 4:**  **Table 1: More Work Required on Group 4 Airplanes Previously Inspected or Changed in Accordance With Revision 1 of This Service Bulletin**  **Repeat Interval (Not to Exceed)** **Compliance Time (Whichever Occurs Lat er)**  **Action Condition** 

- Within 1,000 flight-cyclesafter the Revision 2 date of this service bulletin. Within 3,000 flight-cyclesafter the previous inspection or reworkdone in accordance with Revision 1 of this service bulletin. 7,000 total flight-cyclesGet access to the corner reveals and do amaterial type inspection to determine if the corner reveals arecastings in accordance with Paragraph 3.B., PART 6, or Any affected Group 4 airplanes previouslyinspected in accordance with Revision 1 of this service bulletin:1. But the corner reveals were not replaced. or 2. The corner reveals were replaced with two-piece reveals that were made by rework of existing one-piece reveals in accordance with Revision 1 of this service bulletin. Replace the cornerreveal with a new twopiece corner reveal in accordance with Paragraph 3.B., PART 3.

- - No more work is nec- essary. Any affected Group 4 airplanes previouslyinspected in accordance with Revision 1 of this service bulletin, with new two-piececorner reveals installed. See Table 8

- - Within 10,000 flight-cyclesafter the reveal was replaced.Inspect the corner reveal for cracks in accordance with Table 8, or Any affected Group 4 airplanes previouslyinspected in accordance with Revision 1 of this service bulletin, with new one-piececorner reveals installed. Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3.

- - No more work is nec- essary. Any two-piece corner reveal that is found to not be a casting.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 25 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 4:**  **Table 1: More Work Required on Group 4 Airplanes Previously Inspected or Changed in Accordance With Revision 1 of This Service Bulletin**  **Repeat Interval (Not to Exceed)** **Compliance Time (Whichever Occurs Lat er)**  **Action Condition** 
See Table 8 Before further flight.Inspect the corner reveal for cracks in accordance with Table 8, or Any one or two-piece corner reveal that is found to be a casting.Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3. See Table 8

- Within 6,000 flight-cyclesafter the previous inspection done in accordance with Revision1 of this service bulletin. 10,000 total flight-cyclesInspect the corner reveal for cracks in accordance with Table 8, or Any one-piece corner reveal that is found to not be a casting. Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3.

**Group 1, Configuration 1; Group 4: Table 2: Door 3 Lower Forward Corner Reveal Inspection on Group 1, Configuration 1 and Group 4 Air**  **planes Not Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever Occurs Lat**  **er) Action**  **Condition**

- - Within 1,000 flight-cyclesafter the effective date of AD 2008-18- 07. 1,500 total flight-cyclesDo a material type inspection to determine if the corner revealsare casting in accordance with Paragraph 3.B., PART 6, or All affected airplanes

Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 26 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 1, Configuration 1; Group 4:** **Table 2: Door 3 Lower Forward Corner Reveal Inspection on Group 1, Configuration 1 and Group 4 Air planes Not Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin**  **Repeat Interval (Not to Exceed)** **Compliance Time (Whichever Occurs Lat er)**  **Action Condition** 
Cast corner reveal found See Table 8 Within 3,000 flight-cyclesafter the previous inspection of the door 3 cornerreveal in accordance with SB 747- 53A2378. Within 2,000 flight-cyclesafter the effective date of AD 2008-18- 07. 7,000 total flight-cycles.Inspect the corner reveal for cracks in accordance with Table 8, or Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3. See Table 8

- - Before further flight.Inspect the corner reveal for a sharp edge detail in accordance with Table 7 and Group 4; Cast corner reveal not found

Inspect the corner reveal for cracks in accordance with Table 8, or Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3. See Table 8

- - Before further flight.Inspect the corner reveal for cracks in accordance with Table 8, orGroup 1, Configuration 1; Cast corner reveal not found Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 27 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 1, Configuration 2; Group 2:** **Table 3: Door 3 Lower Forward Corner Reveal Inspection on Group 1, Configuration 2 and Group 2 Air planes Not Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later) Action**  **Condition**
See Table 8 Within 1,000 flight-cycles after the effective date of AD 2008-18-07. Within 1,500 flight-cycles after the corner reveal was replaced in accordance with the original issue of this service bulletin.Inspect the corner reveal for a sharp edge detail in accordance with Table 7 andGroup 1, Configuration 2: All affected airplanes Inspect the corner reveal for cracks in accordance with Table 8, orReplace the corner reveal with a two-piececorner reveal in accordance with Paragraph 3.B., PART 3. See Table 8 Within 1,000 flight-cycles after the effective date of AD 2008-18-07. 1,500 total flight-cycles. Inspect the corner re- veal for a sharp edge detail in accordance with Table 7 andGroup 2: All affected airplanes

Inspect the corner reveal for cracks in accordance with Table 8, orReplace the corner reveal with a two-piececorner reveal in accordance with Paragraph 3.B., PART 3. See Table 8 Within 6,000 flight- cycles. 10,000 total flight-cycles Inspect the corner re-veal for cracks in accordance with Table 8, or No crack, and no sharp edge found.Replace the corner reveal with a two-piececorner reveal in accordance with Paragraph 3.B., PART 3.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 28 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 3:**  **Table 4: Door 3 Lower Forward Corner Reveal Inspection Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever**  **Occurs Later) Action**  **Condition**
See Table 8 Within 1,000 flight-cycles after the effective date of AD 2008-18-07. 10,000 total flight-cycles Inspect the corner reveal for cracks in accordance with Table 8, orAirplanes not previously inspected in accordance with Revision 1 of this service bulletin. Replace the corner revealwith a two-piece corner reveal in accordance with Paragraph 3.B., PART 3. See Table 8

- Within 6,000 flight-cyclesafter the previous inspection. Inspect the corner reveal for cracks in accordance with Table 8, orAirplanes previously inspected in accordance with Revision 1 of this service bulletin, and the existingcorner reveal was not replaced with a new onepiece corner reveal. Replace the corner revealwith a two-piece corner reveal in accordance with Paragraph 3.B., PART 3. See Table 8

- Within10,000 flightcycles after the revealwas replaced. Inspect the corner reveal for cracks in accordance with Table 8, orAirplanes previously inspected in accordance with Revision 1 of this servicebulletin, and the corner reveal was replaced with anew one-piece corner reveal. Replace the corner revealwith a two-piece corner reveal in accordance with Paragraph 3.B., PART 3.

- - No more work is necessary. Reveal was previously re-placed with a two-piece reveal in accordance with Revision 1 of this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 29 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 1, Configuration 1:**  **Table 5: Inspection of Door 3 Lower Forward Corner Reveals on Group 1, Configuration 1 Airplanes Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin**  **Repeat Interval (Not to Exceed)** **Compliance Time (Whichever Occurs Lat er)**  **Action Condition** 
See Table 8

- - Within 10,000 flight-cyclesafter the reveal was replaced.Inspect the corner reveal for cracks in accordance with Table 8, or Airplanes previouslyinspected in accordance with Revision 1 of this service bulletin, and the corner reveal was replaced with a new one-piece corner reveal. Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3. See Table 8

- within 6,000 flight-cyclesafter the previous inspection. 10,000 total flight-cyclesInspect the corner reveal for cracks in accordance with Table 8, or Airplanes previouslyinspected in accordance with Revision 1 of this service bulletin, and the corner reveal is not a casting and was not replaced. Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3. See Table 8 Within 3,000 flight-cycles of the previous inspection of the door 3 corner reveal in accordance with Service Bulletin 747- 53A2378. Within 2,000 flight-cyclesafter the effective date of AD 2008-18- 07. 7,000 total flight-cyclesInspect the corner reveal for cracks in accordance with Table 8, or Airplanes previouslyinspected in accordance with Revision 1 of this service bulletin, and the corner reveal is a casting and was not replaced. Replace the cornerreveal with a twopiece corner reveal in accordance with Paragraph 3.B., PART 3.

- - No more work is nec- essary. Reveal was previouslyreplaced with a twopiece reveal in accordance with Revision 1 of this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 30 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 1, Configuration 2; Group 2:**  **Table 6: Corner Reveal Inspection on Airplanes Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 
See Table 8 Within 6,000 flight-cycles of the previous inspection in accordance with Revision 1 of this service bulletin. 10,000 total flight-cycles Inspect the corner reveal for cracks in accordance with Table 8, orAirplanes previously inspected in accordance with Revision 1 of this servicebulletin, but the corner reveal was not replaced. Replace the corner revealwith a two-piece corner reveal in accordance with Paragraph 3.B., PART 3. See Table 8

- Within10,000 flightcycles after the revealwas replaced. Inspect the corner reveal for cracks in accordance with Table 8, orAirplanes previously inspected in accordance with Revision 1 of this servicebulletin, and the corner reveal was replaced with anew one-piece corner reveal. Replace the corner revealwith a two-piece corner reveal in accordance with Paragraph 3.B., PART 3.

- - No more work is necessary. Reveal was previously re-placed with a two-piece reveal in accordance with Revision 1 of this service bulletin. **Group 1, Configuration 2; Group 2, 4: Table 7 - Inspection of One-Piece Corner Reveals For a Sharp Edge Detail**  **Repeat Interval (Not to Exceed)**  **Compliance Time Action**  **Condition**

- Before further flight. Do a detailed inspection of the installed lower forward corner reveal for a sharp edge detail, in accordance with Paragraph 3.B., PART 1. Group 4 airplanes: At any one-piece corner revealconfirmed to not be a casting.

- Before further flight. Do a detailed inspection of the installed lower forward corner reveal for a sharp edge detail, in accordance with Paragraph 3.B., PART 1. Group 1, Configuration 2 and Group 2 airplanes: At any one-piece corner reveal found.

- Before further flight.Do a detailed inspection of the corner reveal for cracks, in accordance with Table 8. No sharp edge detail found.

- Before further flight. Rework the corner reveal to remove the sharp edge detail in accordance with Paragraph 3.B., PART 1. After rework, do a detailed inspection of the corner reveal for cracks, in accordance with Table 8 Sharp edge detail found

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 31 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 1, 2, 3, 4: Table 8 - Inspection of Corner Reveals for Cracks**  **Repeat Interval (Not to Exceed)**  **Compliance Time Action**  **Condition**

- Before further flight.Do a detailed inspection of the corner reveal for cracks, in accordance with Paragraph 3.B., PART 2. At any corner reveal.

3,000 flight-cycles - Repeat the detailed inspection in accor- dance with Paragraph 3.B., PART 2. Group 1, Configuration 1 and Group 4 airplanes: No cracks found, on a reveal confirmed to be a casting. 6,000 flight-cycles. - Repeat the detailed inspection in accor- dance with Paragraph 3.B., PART 2. Group 1, Configuration 1 and Group 4 airplanes: No cracks found, on a revealconfirmed to not be a casting. Group 1, Configuration 2,Group 2 and Group 3 airplanes: No cracks found.

- Before further flight.Install a two-piece corner reveal in accordance with Paragraph 3.B., PART 3. Group 1, Configuration 1 and Group 4 airplanes: Any crack found on a reveal confirmed to not be a casting. Group 1, Configuration 2,Group 2 and Group 3 airplanes: Any crack found.

- Before further flight.Repair cracks in accordance with Paragraph 3.B., PART 4, and Group 1, Configuration 1 and Group 4 airplanes: Any crackfound on any reveal confirmed to be a casting. 3,000 flight-cyclesWithin 3,000 flightcycles.Do a detailed inspection of the corner reveal for cracks, in accordance with Table 9. or

- Before further flight.Install a two-piece corner reveal in accordance with Paragraph 3.B., PART 3.
**NOTE:**After installation of two-piece door 3 lower forward corner reveals, continue inspections in accordance with the operator's maintenance plan. There are no additional inspections required by this service bulletin. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 32 of 106 **BOEING SERVICE BULLETIN 747-53-2460**If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. The Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the repair and replacement actions with the corresponding compliance times specified in Tables 2, 3, 5, 6, 7 and 8, under paragraph 1.E., "Compliance," of Service Bulletin 747-53-2460, Revision 2 as an AMOC to the repair and replacement actions with the corresponding compliance times required by paragraph paragraph (q) of AD 2007-12-11. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (w) of the AD. These approvals are applicable to the Main Entry Door (MED) 3 lower forward corner reveal only. All provisions of AD 2007-12-11 that are not specifically referenced in this paragraph, including but not limited to performing repeat inspections in accordance with paragraph (o) until a two-piece reveal is installed in accordance with Service Bulletin 747-53-2460 Revision 2, remain fully applicable and must be complied with. The Manager of the FAA Seattle ACO also approves the inspection, rework, repair and replacement actions with the corresponding compliance times specified in Tables 1 through 8, under paragraph 1.E., "Compliance," of Service Bulletin 747-53-2460, Revision 2 as an AMOC to the inspection, rework, repair and replacement actions with the corresponding compliance times required by paragraphs (g), (h), (i), (j) and (k) of AD 2008-18-07. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (p) of the AD. All provisions of AD 2008-18-07 that are not specifically referenced in this paragraph, including but not limited to performing repeat inspections until a two-piece reveal is installed in accordance with Service Bulletin 747-53-2460 Revision 2, remain fully applicable and must be complied with. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this inspection and repair or replacement of the Door 3 Forward Corner Reveal for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. **INSPECTION FOR CRACKS Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 
2.5 5.0 2 Open Access .5 1.0 2 Inspect 2.5 5.0 2 Close Access 5.5 11.0 TOTAL FOR EACH AIRPLANE

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 33 of 106 **BOEING SERVICE BULLETIN 747-53-2460 MATERIAL TYPE INSPECTION**  **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

.5 1.0 2 Remove Finish .25 .5 2 Test .5 1.0 2 Restore Finish 1.25 2.5 TOTAL FOR EACH AIRPLANE
**Corner Reveal Removal and Installation Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 
2.0 4.0 2 Open Access 4.0 8.0 2 Removal / Install 2.0 4.0 2 Close Access .50 1.0 2 Test 8.5 17.0 TOTAL FOR EACH AIRPLANE This estimate does not include the task-hour data given in the service bulletins in Paragraph 1.B., Concurrent Requirements. **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not applicable. **J. References** 1. Existing Data: a. Engineering Change Memo PRR 85901-009SK b. Service Related Problem (SRP)s 747-SRP-53-0129 and 747-SRP-53-0232 c. 747-100/200/300 Aircraft Maintenance Manual (AMM) 20-30-08, 25-21-03, 25-21-04, 51-21-01, 51-21-02, 51-31-01, 52-09-02, 52-11-07, 53-21-02 d. 747-400 Aircraft Maintenance Manual (AMM) 20-30-08, 25-21-03, 25-21-04, 51-21-01, 51-21-02, 51-31-01, 52-09-02, 52-11-07, 53-21-02 e. 747-100/200/300 Structural Repair Manual (SRM) 51-10-02, 51-30-02 f. 747-400 Structural Repair Manual (SRM) 51-20-01, 51-40-02

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 34 of 106 **BOEING SERVICE BULLETIN 747-53-2460**g. Standard Overhaul Practices Manual (SOPM) 20-10-03 , 20-20-02, 20-30-02 , 20-41-02, 20-43-03 , 20-50-10 , 20-50-19 h. Boeing Service Bulletin 747-53A2378 "FUSELAGE-Main Deck Door-Mounted Escape Slide Grit Bar Fittings Inspection, Repair, or Replacement" i. Federal Aviation Administration (FAA) Airworthiness Directive 2007-12-11, 2008-18-07 j. FAA Notice of Proposed Rule Making, FAA Docket Number 2002-NM-285-AD, issued July 13, 2004 k. Boeing Parts Standards Document D-590 l. Boeing Drawing 65B88700 m. Engineering Change Memo PRR 85901-60RS 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number** Forward Frame Instl - No. 3 Entry Door Panel STA 1265 65B01843 Sill Installation - Lower Main No. 3 Entry Door Panel 65B01893 Reveal Installation - No. 3 Main Entry Door 65B08208 Seal Application Instl - Skin Area, Sect. 44 Lower 65B10440 Doorway Lining Installation - No. 3 Doorway 65B50397 Lining Instl - Entry Way, Door 3 411U2223 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications **Chapter-Section Publication**  53-12 747 Illustrated Parts Catalog 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 35 of 106 **BOEING SERVICE BULLETIN 747-53-2460 L. Interchangeability and Intermixability of Parts**  Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 36 of 106 **BOEING SERVICE BULLETIN 747-53-2460 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 **REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION** 
**Unit Price as of May 31, 2006 (US**  **Dollars) ROLT as of May** **31, 2006 (Calen dar Days)**  **Name Kit Number** 

Inactive for procurement Top Kit 015U1697-1 $9,298 35 Top Kit 015U1787-1 $227 35 Kit 015U1787-2 **B. Industry Support Information** Boeing warranty remedies are not available for the inspections and repair procedures given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. If an operator has previously obtained Top Kit 015U1697-1, the 65B11751-605 and 65B11751-606 Reveal Assemblies in that kit can be reworked into the required 65B11751-5 and 65B11751-6 Reveal Assemblies as given in Figures 14 and 15 of this service bulletin.
**Kit 015U1787 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -1**  **-2** (a) Top Kit

- . 015U1787-1 (b) (c) (d) Fastener Kit 2
- 015U1787-2

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 37 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Kit 015U1787**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-1 -2**  (e) (f) (g) 65B11751-601 or 65B11751-605 REVEAL ASSY 1

. 65B11751-5 (65B11751- 11 Optional) (e) (f) (g) 65B11751-602 or 65B11751-606 REVEAL ASSY 1

. 65B11751-6(65B11751- 12 Optional) BOLT

. 2 BACB30NN3K9 BOLT

. 3 BACB30NX6K3Y BOLT

. 11 BACB30NX8K3 BOLT

. 4 BACB30NX8K4X BOLT

. 3 BACB30NY6K16X BOLT

. 3 BACB30NY6K16Y BOLT

. 3 BACB30NY6K17X BOLT

. 3 BACB30NY6K17Y BOLT

. 1 BACB30NY6K3Y BOLT

. 1 BACB30NY8K16X BOLT

. 1 BACB30NY8K16Y BOLT

. 1 BACB30NY8K3 BOLT

. 2 BACB30VF3K3 COLLAR

. 1 BACC30AC6 COLLAR

. 14 BACC30BH8 COLLAR

. 3 BACC30R6 NUT PLATE

. 7 BACN10JN3 NUTPLATE

. 2 BACN10JR3 NUT PLATE

. 3 BACN10JZ3B2 NUT

. 2 BACN10YR3CD NUT

. 3 BACN10YT3CD NUT

. 1 BACN10YT4CD RIVET

. 18 BACR15GF3D4 SHIM, LAMINATED

. 1 BACS40R011C044F(BACS40R011C045Foptional) WASHER, PLAIN

. 15 BACW10BP31DP WASHER, PLAIN

. 15 BACW10BP32DP

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 38 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Kit 015U1787**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-1 -2**  WASHER, FLAT

. 2 NAS1149D0363J RIVET

. 6 NAS1399D4A4 (a) Replacement Top Kit. Replaces original Top Kit 015U1697-1.(b) On Group 2 and 3 airplanes, if the inspection in this service bulletin shows that the existing corner reveal assemblies are not cracked, the existing reveal assemblies can be reworked into the required 65B11751-5 and 65B11751-6 Reveal Assemblies. Only Fastener Kits 015U1787-2 (one for each side of the airplane) would then be required. (c) There are more parts than are necessary. (d) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers used as substitutes. (e) Discard the existing part. (f) This part is used in production. (g) You cannot use the existing part to replace the new or changed part.
**Kit 65B11751 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -5**  **-6 -11**  **-12** REVEAL ASSY

- . . . 65B11751-5 REVEAL ASSY

. - . . 65B11751-6 REVEAL ASSY

. . - . 65B11751-11 REVEAL ASSY

. . . - 65B11751-12 REVEAL 1

. . . 65B11751-1 REVEAL

. 1

. . 65B11751-2 REVEAL 1

. . . 65B11751-3 REVEAL

. 1

. . 65B11751-4 REVEAL

. . 1

. 65B11751-7 REVEAL

. . . 1 65B11751-8 REVEAL

. . 1

. 65B11751-9 REVEAL

. . . 1 65B11751-10

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 39 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Kit 015U1697**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-1 -2**  **-3** (d) Top Kit

- . . 015U1697-1 (b) (c) Subkit - Door 3 Left 1
- . 015U1697-2 (b) (c) Subkit - Door 3 Right 1

. - 015U1697-3 (a) 65B11751-601 Corner Reveal

. 1

. 65B11751-605 (a) 65B11751-602 Corner Reveal

. . 1 65B11751-606 Bolt

. 3 3 BACB30NX6K3Y Bolt

. 11 11 BACB30NX8K3 Bolt

. 2 2 BACB30NX8K4X Bolt

. 2 2 BACB30NN3K9 Bolt

. 3 3 BACB30NY6K16X Bolt

. 3 3 BACB30NY6K16Y Bolt

. 3 3 BACB30NY6K17X Bolt

. 3 3 BACB30NY6K17Y Bolt

. 1 1 BACB30NY6K3Y Bolt

. 1 1 BACB30NY8K16X Bolt

. 1 1 BACB30NY8K3 Bolt

. 2 2 BACB30VF3K3 Bolt

. 1 1 BACB30NY8K16Y Bolt

. 2 2 BACB30NX8K4X Collar

. 1 1 BACC30AC6 Collar

. 14 14 BACC30BH8 Collar

. 3 3 BACC30R6 Nutplate

. 7 7 BACN10JN3 Nutplate

. 2 2 BACN10JR3 Nut

. 2 2 BACN10YR3CD Nutplate

. 3 3 BACN10JZ3B2 Nut

. 3 3 BACN10YT3CD Nut

. 1 1 BACN10YT4CD Rivet

. 18 18 BACR15GF3D4 Shim

. 1 1 BACS40R011C044F Washer

. 15 15 BACW10BP31DP

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 40 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Kit 015U1697**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-1 -2**  **-3** Washer

. 15 15 BACW10BP32DP Washer

. 2 2 NAS1149D0363J Rivet 6 6 NAS1399D4A4 (a) You cannot use the existing part to replace the new or changed part. (b) The Subkits contain more fasteners than are necessary to accomplish this service bulletin. (c) If grip length of fasteners shown in the Subkits are not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers used as substitutes. (d) Superseded by Top Kit 015U1787-1. 2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Specifi-**  **cation**

- Sealant 4 Ounces BMS 5-142 (a)

- Sealant 1 Quart BMS 5-95 (a)

- Primer 4 Ounces BMS 10-11 Type 1 (a) Color 702 White Enamel 4 Ounces BMS 10-60 Type 1 (a) Order Class B1 for 1 hour cure time or Class B1/4 for 15 minute cure time. Fairing Compound 1 Pint EC-3587-B/A (b)

- Corrosion Preventive Compound 1 Ounce MIL-C-11796 Class 3

- Parting Agent 4 Ounces AC962-73C (c) (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) 3M, 3211 E. Chestnut Express Way Springfield Missouri 65802 USA, Phone 417 869-4235, Fax 417-869-5219 (c) AC Products, Inc. 172 East La Jolla Street, Palencia, California 92870 Phone: 714-630-7311
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 41 of 106 **BOEING SERVICE BULLETIN 747-53-2460 D. Parts Necessary to Change Spares**  None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 42 of 106 **BOEING SERVICE BULLETIN 747-53-2460 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:**1. The instructions identified in Paragraph 3.B. Work Instructions and the Figures(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: — Linear dimensions are in inches — Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. — Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch — Angular tolerance is plus or minus 2 degrees — Hole dimensions for standard solid rivets are given in Chapter 51 of the applicable SRM — Torque limits to tighten nuts and bolts are given in Chapter 51 of the applicable SRM 5. If the length of any fastener specified in this service bulletin does not meet the installation standards in Chapter 51 of the applicable SRM, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in Chapter 51 of the applicable SRM may be used. 6. Use the approved fastener and process material substitutions in accordance with Chapter 51 of the applicable SRM. Alternate fasteners are listed in Chapter 51 of the applicable SRM and Boeing Drawing 012W6100. 7. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 43 of 106 **BOEING SERVICE BULLETIN 747-53-2460**8. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 9. Deleted 10. These work instructions refer to procedures included on other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 11. Refer to Appendix A for the procedure for the Door 3 lower forward corner reveal material type inspection. 12. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. The removed part can be discarded if a new or serviceable part is installed. **B. WORK INSTRUCTIONS PART 1 - INSPECTION FOR ONE-PIECE OR TWO-PIECE CORNER REVEALS**  1. Gain access to the left and right Door 3 lower forward corner reveals. Refer to FIGURE 2 as an accepted procedure. 2. Do a general visual inspection in accordance with FIGURE 17 to determine if the installed lower forward corner reveals are one-piece or two-piece corner reveals. 3. At any one-piece corner reveal that is found, do one of the following:
**Group 1, Configuration 2; Group 2, 4:** a. Do a detailed inspection of any one-piece corner reveal for a sharp edge detail in accordance with FIGURE 11. (1) If no sharp edge detail is found, do a detailed inspection of the corner reveal for cracks in accordance with PART 2. (2) If a sharp edge detail is found, rework the reveal in accordance with FIGURE 12 to remove the sharp edge. After rework to remove the sharp edge, do a detailed inspection of the corner reveal for cracks in accordance with PART 2. b. Replace the lower forward corner reveal with a new 2-piece corner reveal as given in PART 3. No further inspections are necessary after the two-piece corner reveal is installed.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 44 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 1, Configuration 1; Group 3:**  a. Do a detailed inspection of any one-piece corner reveal for cracks in accordance with PART 2. b. Replace the lower forward corner reveal with a new 2-piece corner reveal as given in PART 3. No further inspections are necessary after the two-piece corner reveal is installed. **PART 2 - INSPECTION OF ONE-PIECE CORNER REVEALS FOR CRACKS** 1. Inspect any installed one-piece corner reveal for cracks in accordance with FIGURE 3. 2. If no cracks are found, restore access. Refer to FIGURE 2 as an accepted procedure. Put the airplane back to a serviceable condition and continue to do repeat inspections of one-piece corner reveals in accordance with Paragraph 1.E., Compliance. **NOTE:**As an alternative to repeated inspections, replace the corner reveal with a two-piece corner reveal as given in PART 3. No further inspections are necessary after the two-piece corner reveal is installed. 3. If cracks are found, do one of the following: a. Replace the corner reveal with a two-piece corner reveal in accordance with PART 3. No further inspections are necessary after the two-piece corner reveal is installed. b.**Group 1, Configuration 1; Group 4:** If the material type inspection in FIGURE 4 determines that the reveal is a casting, do the weld repair in accordance with PART 4. After repair, continue to do inspections of the repaired corner reveal in accordance with Paragraph 1.E., Compliance. **PART 3 - TWO-PIECE LOWER FORWARD CORNER REVEAL INSTALLATION** 1. Gain additional access to the door corner reveal. Refer to FIGURE 5 as an accepted procedure. 2. Remove the corner reveal in accordance with FIGURE 9. **NOTE:**Uncracked, one-piece 6061 aluminum corner reveals that do not have a sharp edge detail can be reworked into two-piece corner reveals in accordance with PART 5. 3. Install the two-piece corner reveal in accordance with FIGURE 10. 4. Restore access. Refer to FIGURE 2 and FIGURE 5 as accepted procedures. 5. Adjust and test the girt bar mechanism. Refer to the task "Girt Mechanism Adjustment and Test" in 747-100/200/300 AMM 52-11-07 or 747-400 AMM 52-11-07 as an accepted procedure. 6. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 45 of 106 **BOEING SERVICE BULLETIN 747-53-2460 Group 1, Configuration 1; Group 4:**  **PART 4 - CAST ALUMINUM CORNER REVEAL WELD REPAIR** 1. Gain additional access to the corner reveal. Refer to FIGURE 5 as an accepted procedure. 2. Remove the Door Corner Reveal in accordance with FIGURE 7. **NOTE:**The weld repair given in the following step is only applicable to cast aluminum corner reveals. 3. Do the Weld Repair on the Door Corner Reveal in accordance with FIGURE 8. 4. Install the Repaired Door Corner Reveal in accordance with FIGURE 7. 5. Restore access. Refer to FIGURE 2 and FIGURE 5 as accepted procedures. 6. Adjust and test the girt bar mechanism. Refer to the task "Girt Mechanism Adjustment and Test" in 747-100/200/300 AMM 52-11-07 or 747-400 AMM 52-11-07 as an accepted procedure. 7. Put the airplane back to a serviceable condition. **PART 5 - REWORK OF A ONE-PIECE CORNER REVEAL INTO A TWO-PIECE CORNER REVEAL** 1. Gain additional access to the corner reveal. Refer to FIGURE 5 as an accepted procedure. 2. Remove the corner reveal in accordance with FIGURE 9. **NOTE:**Only uncracked, one-piece 6061 aluminum corner reveals that do not have a sharp edge detail can be reworked into two-piece corner reveals in accordance with PART 5. Do not rework one-piece cast aluminum fittings. FIGURE 4 includes a procedure to identify corner reveal material types. 3. Rework the left side corner reveal into a 2-piece corner reveal in accordance with FIGURE 13. 4. Rework the right side corner reveal into a 2-piece corner reveal in accordance with FIGURE 14. **Group 1, Configuration 1; Group 4: PART 6 - MATERIAL TYPE INSPECTION**  1. Gain access to the affected (left and/or right) Door 3 lower forward corner reveals. Refer to FIGURE 2 as an accepted procedure. 2. Do the material type inspection in accordance with FIGURE 4 to determine if the corner reveal is a casting. 3. If the material type inspection determines that the corner reveal is a casting, replace the cast reveal with a two-piece machined aluminum reveal in accordance with Paragraph 1.E., Compliance. 4. If the material type inspection determines that the corner reveal is not a casting, continue to do inspections or replace with a two-piece machined reveal in accordance with Paragraph 1.E., Compliance. Restore access. Refer to FIGURE 2 as an accepted procedure. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2: December 22, 2010 46 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 1: LOGIC DIAGRAM**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 47 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION**  **(SHEET 1 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 48 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION**  **(SHEET 2 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 49 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION**  **(SHEET 3 OF 7)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 50 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

**FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION (SHEET 4 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 51 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** ACCESS Refer to 747-100/200/300 AMM 25-21-03 or 747- 400 AMM 25-21-03 as an accepted procedure. 1
- Doorway Scuff Plate Remove / Keep 1

12
- Fasteners Keep Fasteners. Refer to 747-100/200/300 AMM 25-21-03 or 747-400AMM 25-21-03 as an accepted procedure. 1
- Forward Corner Scuff Plate Remove / Keep 2

7
- Fasteners

Refer to 747-100/200/300 AMM 25-21-03 or 747- 400 AMM 25-21-03 as an accepted procedure. 1
- Aft Corner Scuff Plate Remove / Keep 3

5
- Fasteners 39
- Fasteners Remove / Keep 4 1
- Threshold Clean Sealant from Doorway Scuff Plate, Fwd andAft Scuff Plates, Threshold and Structure. Refer to 747-100/200/300 AMM 25-21-03 or 747-400AMM 25-21-03 as an accepted procedure. - - Sealant Clean 5

RESTORATION Fay Surface Seal with BMS 5-95 Sealant. See Flagnotes 1, 2 and 3. 1
- Threshold Install / Kept 6

Install with BMS 5-95 Sealant under Bolt Head. Use Protection Sealant Method 1 as given in SOPM 20-50-19 as an accepted procedure. 39
- Fasteners

**FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION (SHEET 5 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 52 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** Refer to 747-100/200/300 AMM 25-21-03 or 747- 400 AMM 25-21-03 as an accepted procedure. 1
- Aft Corner Scuff Plates Install / Kept 7

Install with BMS 5-95 Sealant under Bolt Head. Use Protection Sealant Method 1 as given in SOPM 20-50-19 as an accepted procedure. 5
- Fasteners

Refer to 747-100/200/300 AMM 25-21-03 or 747- 400 AMM 25-21-03 as an accepted procedure. 1
- Fwd Corner Scuff Plates Install / Kept 8

Install with BMS 5-95 Sealant under Bolt Head. Use Protection Sealant Method 1 as given in SOPM 20-50-19 as an accepted procedure. 7
- Fasteners

Fay Surface Seal with BMS 5-95 Sealant. Refer to 747-100/200/300 AMM 25-21-03 or 747-400AMM 25-21-03 as an accepted procedure. See Flagnote 3. 1
- Doorway Scuff Plate Install / Kept 9

Install with BMS 5-95 Sealant under Bolt Head. Use Protection Sealant Method 1 as given in SOPM 20-50-19 as an accepted procedure. 12
- Fasteners Install / Kept

Fillet seal edges of Corner Scuff Plates with BMS 5-95. Refer to 747- 100/200/300 AMM 25-21- 03 or 747-400 AMM 25- 21-03 as an accepted procedure. 1
- Fillet Seal Install 10

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

**FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION (SHEET 6 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 53 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME FLAG**  **NOTE** Prepack cavity with sealant. Use the removable faying surface seal application method. Refer to 747-100/200/300 AMM 51-31-01 or 747-400 AMM 51-31-01 as an accepted procedure. - AC962-73C Parting Agent 1

- BMS 5-95 Sealant
Fay Surface Seal. Use the removable faying surface seal application method. Refer to 747- 100/200/300 AMM 51-31-01 or 747-400 AMM 51- 31-01 as an accepted procedure. - AC962-73C Parting Agent 2

- BMS 5-95 Sealant
Apply a bead of sealant 0.17 - 0.23 inches high by 0.17 - 0.23 inches wide under the Threshold. Use BMS 5-95. Do not block the Drain Holes. Refer to 747-100/200/300 AMM 51-31-01 or 747- 400 AMM 51-31-01 as an accepted procedure. - BMS 5-95 Drain Sealant Bead 3

Fay Surface Seal the joint between Door Scuff Plate and Threshold and joint between the DoorScuff Plate and Corner Scuff Plates. Use the removable faying surface seal application method. Refer to 747-100/200/300 AMM 51-31-01 or 747- 400 AMM 51-31-01 as an accepted procedure. - AC962-73C Parting Agent 4

- BMS 5-95 Sealant

**FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION (SHEET 7 OF 7)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 54 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

**FIGURE 3: DOOR CORNER REVEAL - INSPECTION FOR CRACKS (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 55 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** Do a Detailed Inspection for cracks. Inspect the upper and lower surface of the Corner Reveal. 1 65B11751-601 (Left) Corner Reveal Inspect 1

1 65B11751-602 (Right)

**FIGURE 3: DOOR CORNER REVEAL - INSPECTION FOR CRACKS (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 56 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 4: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 57 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  Refer to 747-100/200/300 AMM 51-21-01 or 747-400 AMM 51-21- 01 as an accepted procedure. - - Finish Remove 1

See APPENDIX A 1 65B11751-601 or 65B11751-605 (Left) Corner Reveal Inspect 2

1 65B11751-602 or 65B11751-606 (Right) Restore finish to the Corner Reveal. Alodine and apply 1 coat of BMS 10-11 Type 1 Primer. Refer to 747-100/200/300 SRM 51-10- 02, 747-400 SRM 51-20-01, and SOPM 20-41-02 or as an accepted procedure. - - Finish Apply 3

**FIGURE 4: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 58 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  ACCESS Refer to 747-100/200/300 AMM 25-21-03 or 747- 400 AMM 25-21-03 as an accepted procedure. 1
- Dado Panel Remove / Keep 1

**FIGURE 5: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL REMOVAL AND INSTALLATION (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 59 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** Refer to 747-100/200/300 AMM 25-21-03 or 747- 400 AMM 25-21-03 as an accepted procedure. 1
- Doorway Side Lin- ing Remove / Keep 2

Refer to 747-100/200/300 AMM 53-21-02 or 747- 400 AMM 53-21-02 as an accepted procedure. - - Floor Panels Remove / Keep 3

Refer to 747-100/200/300 AMM 25-21-04 or 747- 400 AMM 25-21-04 as an accepted procedure. 1
- Insulation Remove / Keep 4

RESTORATION Refer to 747-100/200/300 AMM 25-21-04 or 747- 400 AMM 25-21-04 as an accepted procedure. 1
- lnsulation Install / Kept 5

Refer to 747-100/200/300 AMM 53-21-02 or 747- 400 AMM 53-21-02 as an accepted procedure. - - Floor Panels Install / Kept 6

Refer to 747-100/200/300 AMM 25-21-03 or 747- 400 AMM 25-21-03 as an accepted procedure. 1
- Doorway Side Lin- ing Install / Kept 7

Refer to 747-100/200/300 AMM 25-21-03 or 747- 400 AMM 25-21-03 as an accepted procedure. 1
- Dado Panel Install / Kept 8

**FIGURE 5: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL REMOVAL AND INSTALLATION (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 60 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT**  **(SHEET 1 OF 9)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 61 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT**  **(SHEET 2 OF 9)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 62 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT**  **(SHEET 3 OF 9)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 63 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each side of the airplane.

**FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT (SHEET 4 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 64 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP**

- 2
- Fasteners Remove / Discard 1

- 1
- Girt Bar Fitting Remove / Keep

- 1
- Plate Remove / Keep

- 2
- Fasteners Remove / Discard 2

- 18
- Fasteners Remove / Discard 3 See Flagnote 1 1 65B11751-601 (left) Corner Reveal Remove / Discard 1 65B11751-602 (right) Remove if installed. 1
- Shim

- 2
- Nutplates Remove / Discard 4 From the structure. Refer to 747-100/200/300 AMM 20- 30-08 or 747-400 AMM 20-30-08 as an accepted procedure. - - Sealant Clean 5

(a) 1 65B11751-605 (left) Corner Reveal Position 6 1 65B11751-606 (right) If required. See Flagnote 2 1 BACS40R011C044F Shim

- 22
- Holes Back Drill 7

- 4
- Temporary Fasten- ers Install 8 Removed in Figure 2. 1
- Threshold Position Kept 9 3 0.190 - 0.199 Holes Back Drill 10 Removed in Figure 2. 1
- Doorway Scuff Plate Position Kept 11 at nutplate location. 1 0.190 - 0.199 Holes Back Drill 12 Removed in Figure 2. 1
- Forward Position Kept 13 Corner Scuff Plate at nutplate locations. 3 0.190 - 0.199 Holes Back Drill 14

- 1 Corner Scuff Plate Remove / Keep 15

- 1
- Doorway Scuff Plate Remove / Keep 16

- 1
- Threshold Remove / Keep 17

**FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT (SHEET 5 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 65 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP**

- 4
- Temporary Fasten- ers Remove / Discard 18

- 1 65B11751-605 (left) Corner Reveal Remove / Keep

- 1 65B11751-606 (right)

- 1 BACS40R011C044F Shim

- 7
- Nutplates Position 19

- 14
- Holes Back Drill 20 All drilled holes.

- - Holes Clean / Debur 21 Install rivets wet with BMS 5- 95 Sealant. 2 BACN10JZ3B2 Nut Plates Install 22

- 7
- Nut Plates Install 23 Install with Fay Surface Sealant. See Flagnote 3. 1 65B11751-605 (left) Corner Reveal Install / Kept 24 1 65B11751-606 (right) If required. See Flagnote 2 1 BACS40R011C044F Shim Install wet with BMS 5-95 Sealant. See Flagnote 4. 20
- Fasteners Install See Flagnote 5 and 6.

- EC-3587-B/A Fairing Compound Apply 25 Apply over Fairing Compound. Refer to SOPM 20-41-02 as an accepted procedure. - BMS 10-11 Type 1 Primer Apply 26

Boeing Color 702 White Refer to 747-100/200/300 AMM 51-21-02 or 747-400 AMM 51-21-02 as an accepted procedure. BMS 10-60 Type 1 Enamel Apply 27

Install wet with BMS5-95 Sealant. 2
- Fasteners Install 28 Install with Fay Surface Sealant. See Flagnote 7. 1
- Plate Install / Kept 29

- 1
- Girt Bar Fitting Install with MIL-C-11796, Class 3 corrosion preventive compound to all areas of the hole and on the fasteners. 2 BACB30NN3K9 Fasteners Install

(a) Prior to installation of the new corner reveal, do an inspection for a sharp edge detail as given in Part 1 of the Accomplishment Instructions. Rework the reveal to remove the sharp edge as shown in Part 1 of

**FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT (SHEET 6 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 66 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** the Accomplishment Instructions if necessary. Do not install a reveal which has the sharp edge detail described in Part 1 of the Accomplishment Instructions. The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**NOTES QTY**  **PART NUMBER NAME**  **FLAG NOTE**  Some airplanes may have the nutplates attach with rivets that go through the Corner Reveal andthe bracket below. For this configuration the nutplate attach rivets must be removed before the Corner Reveal can be removed. 4
- Fasteners 1

Install Shim as required to maintain a maximum gap of 0.010 gap. Finish with BMS 10-11 Type 1 Primer after delaminations are removed. Shim can be installed with the primer wet or dry. Refer to SOPM 20-41-02 as an accepted procedure. 1
- Shim 2

Apply fay surface seal between Outboard side of Corner Reveal and Skin strap. Refer to 747- 100/200/300 AMM 51-31-01 or 747-400 AMM 51- 31-01 747-400 AMM 51-31-01 as an accepted procedure. - BMS 5-95 Fay Surface Seal 3

Grinding off the end of Bolt is allowed. Grind so that end of bolt is even with the surface of the Corner Reveal. Do not grind the nut. - Bolt Grind 4

Make a seal ramp between the Corner Reveal and Door Frame. Grind Compound to match contourof seal plane. Grind smooth to touch (125 microinches or less) fill small voids with BMS 5-142.Do the Air Leak and Seal Contact Surface Inspection to verify the seal contact on the seal ramp. Refer to SOPM 20-50-19 and 747-100/200/300 AMM 52-09-02 or 747-400 AMM 52-09-02 as an accepted procedure. - - Fairing Compound 5

Fill Fastener Holes with Fairing Compound. For fastener holes that are not under the seal ramp, grind flush with the Revel. - - Fairing Compound 6

Apply fay surface seal between Plate and Corner Reveal. Refer to 747-100/200/300 AMM 51-31-01 or 747-400 AMM 51-31-01 747-400 AMM 51-31- 01 as an accepted procedure. - BMS 5-95 Fay Surface Seal 7

**FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT (SHEET 7 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 67 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65B88700 are used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE** 0.190 - 0.194 BACB30NN3K9 Bolt A 0.1890 - 0.1905 BACB30VF3K3 Bolt B
NAS1149D0363J Washer BACN10YR3CD Nut 0.129 - 0.132 NAS1399D4A4 Rivet C 0.2021 - 0.2036 BACB30NY6K16X Bolt (a) D
0.2021 - 0.2036 BACB30NY6K17X Bolt (a)
BACN10JC3CD Nut 0.2177 - 0.2192 BACB30NY6K16Y Bolt (a)
0.2177 - 0.2192 BACB30NY6K17Y Bolt (a)

**FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT (SHEET 8 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 68 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **HOLE DIA PART NUMBER**  **NAME CODE**  0.2646 - 0.2661 BACB30NY8K16X Bolt (b) E
0.2802- 0.2817 BACB30NY8K16Y Bolt (b)
BACN10YT4CD Nut 0.216 - 0.219 BACB30NX6K3Y Bolt (c) F BACC30R6 Collar (c) 0.247 - 0.250 BACB30NX8K3 Bolt (c) BACC30BH8 Collar (c) 0.216 - 0.219 BACB30NY6K3Y Bolt (d) G BACC30AC6 Collar (d) 0.247 - 0.250 BACB30NW8K3 Bolt (d) BACC30BL8 Collar (d) 0.247 - 0.250 BACB30NX8K3 Bolt H BACC30BH8 Collar 0.263 - 0.266 BACB30NX8K4X Bolt I BACC30BH8 Collar BACN10JN3 Nutplate J BACN10JR3 Nutplate K 0.098 - 0.103 BACR15GF3D4 Rivet L (a) Bolts of 2 diameters and 2 grip lengths are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the appropriate grip length bolt. Refer to 747-100/200/300 SRM 51- 30-02 or 747-400 SRM 51-40-02. (b) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02. (c) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the BACC30R6 Collar with the BACB30NX6K3Y Bolt. Use the BACC30BH8 Collar with the BACB30NX8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02. (d) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the BACC30AC6 Collar with the BACB30NY6K3Y Bolt. Use the BACC30BL8 Collar with the BACB30NW8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

**FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT (SHEET 9 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 69 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR**  **(SHEET 1 OF 8)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 70 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR**  **(SHEET 2 OF 8)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 71 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each side of the airplane.

**FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR (SHEET 3 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 72 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP**

- 2
- Fasteners Remove / Discard 1

- 1
- Girt Bar Fitting Remove / Keep

- 1
- Plate Remove / Keep

- 2
- Fasteners Remove / Discard 2

- 18
- Fasteners Remove / Discard 3 See Flagnote 1 1 65B11751-601 (left) Corner Reveal Remove / Keep 1 65B11751-602 (right) If installed. 1
- Shim Remove / Discard 9
- Nutplates Remove / Discard 4 From the structure and the Corner Reveal. Refer to 747-100/200/300 AMM 20-30-08 and 747-400AMM 20-30-08 as an accepted procedure. - - Sealant Clean 5

AFTER WELD REPAIR

- 1 65B11751-601 (left) Corner Reveal Position / Kept 6

- 1 65B11751-602 (right) If required. See Flagnote 2 1 BACS40R011C044F Shim

- 22
- Holes Back Drill 7

- 1 65B11751-601 (left) Corner Reveal Remove / Keep 8

- 1 65B11751-602 (right)

- 1 BACS40R011C044F Shim All drilled holes.

- - Holes Clean / Debur 9

- 7
- Nutplates Install 10 Install rivets wet with BMS 5-95 Sealant. 2 BACN10JZ3B2 Nut Plates Install 11 Install with Fay Surface Sealant. See Flagnote 3. 1 65B11751-601 (left) Corner Reveal Install / Kept 12

- 1 65B11751-602 (right) If required. See Flagnote 2 1 BACS40R011C044F Shim Install
Install wet with BMS 5-95 Sealant. See Flagnote 4 20
- Fasteners

**FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR (SHEET 4 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 73 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** See Flagnotes 5 and 6

- EC-3587-B/A Fairing Compound Apply 13 Apply over Fairing Compound. Refer to SOPM 20-41-02 SOPM 20-41-02as an accepted procedure. - BMS 10-11 Type 1 Primer Apply 14

Boeing Color 702 White Refer to 747-100/200/300 AMM 51-21-02 or 747- 400 AMM 51-21-02 as an accepted procedure. BMS 10-60 Type 1 Enamel Apply 15

Install wet with BMS5-95 Sealant. 2
- Fasteners Install 16 Install with Fay Surface Sealant. See Flagnote 7. 1
- Plate Install / Kept 17

- 1
- Girt Bar Fitting Install with MIL-C-11796,Class 3 corrosion preventive compound to all areas of the hole and on the fasteners. 2 BACB30NN3K9 Fasteners Install

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**NOTES QTY**  **PART NUMBER NAME**  **FLAG NOTE**  Some airplanes may have the nutplates attach with rivets that go through the Corner Reveal andthe bracket below. For this configuration the nutplate attach rivets must be removed before the Corner Reveal can be removed. 4
- Fasteners 1

Install Shim as required to maintain a maximum gap of 0.010 gap. Finish with BMS 10-11 Type 1 Primer after delaminations are removed. Shim can be install with the primer wet or dry. Refer to SOPM 20-41-02 as an accepted procedure. 1
- Shim 2

Apply fay surface seal between Outboard side of Corner Reveal and Skin strap. Refer to 747- 100/200/300 AMM 51-31-01 or 747-400 AMM 51- 31-01 as an accepted procedure. - BMS 5-95 Fay Surface Seal 3

**FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR (SHEET 5 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 74 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME FLAG**  **NOTE** Grinding off the end of Bolt is allowed. Grind so that end of bolt is even with the surface of the Corner Reveal. Do not grind the nut. - Bolt Grind 4

Make a seal ramp between the Corner Reveal and Door Frame. Grind Compound to match contourof seal plane. Grind smooth to touch (125 microinches or less) fill small voids with BMS 5-142.Do the Air Leak and Seal Contact Surface Inspection to verify the seal contact on the seal ramp. Refer to 747-100/200/300 AMM 52-09-02 or 747- 400 AMM 52-09-02 and SOPM 20-50-19 as an accepted procedure. - - Fairing Compound 5

Fill Fastener Holes with Fairing Compound. For fastener holes that are not under the seal ramp, grind flush with the Revel. - - Fairing Compound 6

Apply fay surface seal between Plate and Corner Reveal. Refer to 747-100/200/300 AMM 51-31-01or 747-400 AMM 51-31-01 as an accepted procedure. - BMS 5-95 Fay Surface Seal 7

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65B88700 are used to determine the part numbers used as substitutes.

**FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR (SHEET 6 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 75 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **HOLE DIA PART NUMBER**  **NAME CODE**  0.190 - 0.194 BACB30NN3K9 Bolt A 0.1890 - 0.1905 BACB30VF3K3 Bolt B
NAS1149D0363J Washer BACN10YR3CD Nut 0.129 - 0.132 NAS1399D4A4 Rivet C 0.2021 - 0.2036 BACB30NY6K16X Bolt (a) D
0.2021 - 0.2036 BACB30NY6K17X Bolt (a)
BACN10JC3CD Nut 0.2177 - 0.2192 BACB30NY6K16Y Bolt (a)
0.2177 - 0.2192 BACB30NY6K17Y Bolt (a)
0.2646 - 0.2661 BACB30NY8K16X Bolt (b) E
0.2802- 0.2817 BACB30NY8K16Y Bolt (b)
BACN10YT4CD Nut 0.216 - 0.219 BACB30NX6K3Y Bolt ((c) F BACC30R6 Collar (c) 0.247 - 0.250 BACB30NX8K3 Bolt (c) BACC30BH8 Collar (c) 0.216 - 0.219 BACB30NY6K3Y Bolt (d) G BACC30AC6 Collar (d) 0.247 - 0.250 BACB30NW8K3 Bolt (d) BACC30BL8 Collar (d) 0.247 - 0.250 BACB30NX8K3 Bolt H BACC30BH8 Collar 0.263 - 0.266 BACB30NX8K4X Bolt I BACC30BH8 Collar BACN10JN3 Nutplate J BACN10JR3 Nutplate K

**FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR (SHEET 7 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 76 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **HOLE DIA PART NUMBER**  **NAME CODE**  0.098 - 0.103 BACR15GF3D4 Rivet L (a) Bolts of 2 diameters and 2 grip lengths are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the appropriate grip length bolt. Refer to 747-100/200/300 SRM 51- 30-02 or 747-400 SRM 51-40-02. (b) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02. (c) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the BACC30R6 Collar with the BACB30NX6K3Y Bolt. Use the BACC30BH8 Collar with the BACB30NX8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02. (d) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the BACC30AC6 Collar with the BACB30NY6K3Y Bolt. Use the BACC30BL8 Collar with the BACB30NW8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

**FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR (SHEET 8 OF 8)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 77 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one Corner Reveal.
**NOTES QTY**  **PART NUMBER NAME**  **TASK STEP**  Remove all the finish from the Corner Reveal. 1
- Finish Remove 1 Refer to 747-100/200/300 AMM 51-21-01 or 747- 400 AMM 51-21-01 as an accepted procedure. Fusion weld repair as given in BAC 5975, Class B, using filler material ER 4043 per AWS A5.10 or AMS 4190 1
- Crack Weld 2

Machine welded area to original contour. Machine to 125 microinch finish or better. 1
- Weld Area Machine 3

Heat to 300 to 320 degrees Fahrenheit for 1 to 6 hours. 1 65B11751-601 or 65B11751-602 Corner Reveal Heat Treat 4

**FIGURE 8: DOOR CORNER REVEAL - WELD REPAIR (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 78 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** Inspect for cracks. Do a 10 power visual and a Dye Penetrant inspection. Refer to SOPM 20-20-02as an accepted procedure. 1 65B11751-601 or 65B11751-602 Corner Reveal Inspect 5

Restore finish to the Corner Reveal. Alodine and apply 1 coat of BMS 10- 11 Type 1 Primer. Refer to 747-100/200/300 SRM 51-10-02 or 747-400 SRM 51-20-01 and SOPM 20-41-02 as an accepted procedure. 1
- Finish Apply 6

**FIGURE 8: DOOR CORNER REVEAL - WELD REPAIR (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 79 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 9: DOOR CORNER REVEAL REMOVAL**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 80 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each side of the airplane.

**FIGURE 9: DOOR CORNER REVEAL REMOVAL (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 81 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP**

- 2
- Fasteners Remove / Discard 1

- 1
- Girt Bar Fitting Remove / Keep

- 1
- Plate Remove / Keep

- 2
- Fasteners Remove / Discard 2

- 18
- Fasteners Remove / Discard 3 See Flagnote 1 1
- Corner Reveal Remove / Discard if installed. 1
- Shim

- 2
- Nutplates Remove / Discard 4 From the structure. Refer to 747-100/200/300 AMM 20-30-08 and 747-400AMM 20-30-08 as an accepted procedure. - - Sealant Clean 5

The flag note numbers shown below agree with the numbers shown in the flag symbol in the figure.
**NOTES QTY**  **PART NUMBER NAME**  **FLAG NOTE**  Some airplanes may have the nutplates attached with rivets that go through the Corner Reveal andthe bracket below. For this configuration the nutplate attach rivets must be removed before the Corner Reveal can be removed. 4
- Fasteners 1

**FIGURE 9: DOOR CORNER REVEAL REMOVAL (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 82 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION**  **(SHEET 1 OF 9)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 83 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION**  **(SHEET 2 OF 9)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 84 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION**  **(SHEET 3 OF 9)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 85 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each side of the airplane.

**FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION (SHEET 4 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 86 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** Left side 1 65B11751-1 (Option- al: 65B11751-7) Upper Portion of Corner Reveal Position 1 Right side 65B11751-2 (Option- al: 65B11751-8) If required. See Flagnote 2 1 BACS40R011C044F Shim Left side 1 65B11751-3 (Option- al: 65B11751-9) Lower Portion of Corner Reveal Position 2 Right side 65B11751-4 (Option- al: 65B11751-10)

- 22
- Holes Back Drill 3

- 4
- Temporary Fasten- ers Install 4

- 1
- Threshold Position Kept 5

- 3 0.190 - 0.199 Holes Back Drill 6

- 1
- Doorway Scuff Plate Position Kept 7 at nutplate location. 1 0.190 - 0.199 Holes Back Drill 8 1
- Forward Position Kept 9 Corner Scuff Plate at nutplate locations. 3 0.190 - 0.199 Holes Back Drill 10

- 1
- Corner Scuff Plate Remove / Keep 11

- 1
- Doorway Scuff Plate Remove / Keep 12

- 1
- Threshold Remove / Keep 13

- 4
- Temporary Fasten- ers Remove / Discard 14

1
- Upper Corner Re- veal Remove / Keep

1
- Shim 1
- Lower Corner Re- veal Remove / Keep

- 7
- Nutplates Position 15

- 14
- Holes Back Drill 16 All drilled holes.

- - Holes Clean / Debur 17

**FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION (SHEET 5 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 87 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME TASK**  **STEP** Install rivets wet with BMS 5-95 Sealant. 2 BACN10JZ3B2 Nut Plates Install 18

- 7
- Nut Plates Install 19 Install with Fay Surface Sealant. See Flagnote 3. 1
- Upper Corner Re- veal Install / Kept 20 If required. See Flagnote 2 1
- Shim Install with Fay Surface Sealant. See Flagnote 3. 1
- Lower Corner Re- veal Install / Kept
Install wet with BMS 5-95 Sealant. See Flagnote 4. 20
- Fasteners Install Fill the gap between the upper and lower corner reveals with sealant. Make the sealant flush with both parts of the reveal. - BMS 5-95 Sealant Apply 21

See Flagnote 5 and 6.

- EC-3587-B/A Fairing Compound Apply 22 Apply over Fairing Compound. Refer to SOPM 20-41-02 or Operators equivalent procedure. - BMS 10-11 Type 1 Primer Apply 23

Boeing Color 702 White Refer to 747-100/200/300 AMM 51-21-02 or 747-400AMM 51-21-02 as an accepted procedure. - BMS 10-60 Type 1 Enamel Apply 24

Install wet with BMS 5-95 Sealant. 2
- Fasteners Install 25 Install with Fay Surface Sealant. See Flagnote 7. 1
- Plate Install / Kept 26

- 1
- Girt Bar Fitting Install with MIL-C-11796, Class 3 corrosion preventive compound to all areas of the hole and on the fasteners. 2 BACB30NN3K9 Fasteners Install

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

**FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION (SHEET 6 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 88 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **QTY PART NUMBER**  **NAME FLAG**  **NOTE** Some airplanes may have the nutplates attach with rivets that go through the Corner Reveal andthe bracket below. For this configuration the nutplate attach rivets must be removed before the Corner Reveal can be removed. 4
- Fasteners 1

Install Shim as required to maintain a maximum gap of 0.010 gap. Finish with BMS 10-11 Type 1 Primer after delaminations are removed. Shim can be installed with the primer wet or dry. Refer to SOPM 20-41-02 as an accepted procedure. 1
- Shim 2

Apply fay surface seal between Outboard side of Corner Reveal and Skin strap. Refer to 747- 100/200/300 AMM 51-31-01 or 747-400 AMM 51- 31-01 as an accepted procedure. - BMS 5-95 Fay Surface Seal 3

Grinding off the end of Bolt is allowed. Grind so that end of bolt is even with the surface of the Corner Reveal. Do not grind the nut. - Bolt Grind 4

Make a seal ramp between the Corner Reveal and Door Frame. Grind Compound to match contourof seal plane. Grind smooth to touch (125 microinches or less) fill small voids with BMS 5-142.Do the Air Leak and Seal Contact Surface Inspection to verify the seal contact on the seal ramp. Refer to SOPM 20-50-19 and 747-100/200/300 AMM 52-09-02 or 747-400 AMM 52-09-02 as an accepted procedure. - - Fairing Compound 5

Fill Fastener Holes with Fairing Compound. For fastener holes that are not under the seal ramp, grind flush with the Revel. - - Fairing Compound 6

Apply fay surface seal between Plate and Corner Reveal. Refer to 747-100/200/300 AMM 51-31-01or 747-400 AMM 51-31-01 as an accepted procedure. - BMS 5-95 Fay Surface Seal 7

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener.

**FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION (SHEET 7 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 89 of 106 **BOEING SERVICE BULLETIN 747-53-2460**If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65B88700 are used to determine the part numbers used as substitutes.
**NOTES HOLE DIA**  **PART NUMBER NAME**  **CODE**

- 0.190 - 0.194 BACB30NN3K9 Bolt A

- 0.1890 - 0.1905 BACB30VF3K3 Bolt B

- NAS1149D0363J Washer BACN10YR3CD Nut

- 0.129 - 0.132 NAS1399D4A4 Rivet C

- 0.2021 - 0.2036 BACB30NY6K16X Bolt (a) D 0.2021 - 0.2036 BACB30NY6K17X Bolt (a) BACN10YT3CD optional (e)

- BACN10JC3CD Nut

- 0.2177 - 0.2192 BACB30NY6K16Y Bolt (a) 0.2177 - 0.2192 BACB30NY6K17Y Bolt (a)

- 0.2646 - 0.2661 BACB30NY8K16X Bolt (b) E 0.2802- 0.2817 BACB30NY8K16Y Bolt (b)

- BACN10YT4CD Nut

- 0.216 - 0.219 BACB30NX6K3Y Bolt (c) F

- BACC30R6 Collar (c) 0.247 - 0.250 BACB30NX8K3 Bolt (c)

- BACC30BH8 Collar (c)

**FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION (SHEET 8 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 90 of 106 **BOEING SERVICE BULLETIN 747-53-2460 NOTES**  **HOLE DIA PART NUMBER**  **NAME CODE** 

- 0.216 - 0.219 BACB30NY6K3Y Bolt (d) G

- BACC30AC6 Collar (d) 0.247 - 0.250 BACB30NW8K3 Bolt (d)

- BACC30BL8 Collar (d)

- 0.247 - 0.250 BACB30NX8K3 Bolt H

- BACC30BH8 Collar

- 0.263 - 0.266 BACB30NX8K4X Bolt I

- BACC30BH8 Collar

- - BACN10JN3 Nutplate J

- - BACN10JR3 Nutplate K

- 0.098 - 0.103 BACR15GF3D4 Rivet L (a) Bolts of 2 diameters and 2 grip lengths are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the appropriate grip length bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02. (b) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02. (c) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the BACC30R6 Collar with the BACB30NX6K3Y Bolt. Use the BACC30BH8 Collar with the BACB30NX8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02. (d) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean hole. Use the BACC30AC6 Collar with the BACB30NY6K3Y Bolt. Use the BACC30BL8 Collar with the BACB30NW8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02. (e) If the BACN10YT3CD nuts are ever removed, discard them. Do not reuse BACN10YT( ) nuts.

**FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION (SHEET 9 OF 9)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 91 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 11: INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 92 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.

**FIGURE 11: INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 93 of 106 **BOEING SERVICE BULLETIN 747-53-2460 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** Do a Detailed Inspection for cracks. 1
- Corner Reveal Assy Inspect 1 Do a Detailed Inspection for a sharp edge. 1
- Corner Reveal Assy Inspect 2

**FIGURE 11: INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 94 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each corner reveal.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  The sharp edge the minimum amount necessary to get the dimension shown. - - Corner Reveal Assy Cut 1 Radius both cut edges and blend to get a63 microinch or smoother surface roughness. Refer to SOPM 20-10-03 as an accepted procedure. - - Corner Reveal Assy Blend 2

**FIGURE 12: REMOVAL OF THE SHARP EDGE DETAIL FROM THE DOOR CORNER REVEAL (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 95 of 106 **BOEING SERVICE BULLETIN 747-53-2460 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** The cut edge and adjacent upper and lower surfaces (intensity 0.004A - 0.007A, coverage 2.0, shot size 230 - 550). Referto SOPM 20-10-03 as an accepted procedure. - - Corner Reveal Assy Shot Peen 3

Chemical conversion coating to the reworked area of the reveal. Refer to SOPM 20-43-03 as an accepted procedure. - - Finish Apply 4

One coat of BMS 10-11, Type I primer to the reworked area of the reveal. Refer toSOPM 20-41-02 as an accepted procedure. - - Finish Apply

**FIGURE 12: REMOVAL OF THE SHARP EDGE DETAIL FROM THE DOOR CORNER REVEAL (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 96 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 13: REWORK OF A 1-PIECE LEFT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR CORNER**  **REVEAL (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 97 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each affected left side corner reveal. **NOTE:**These rework instructions are only allowed on 65B11751-601 corner reveals which have been confirmed to be machined from 6061-T6 plate, not 356 aluminum castings. See Figure 4 to determine material. All 65B11751-605 corner reveals are machined from 6061-T6 plate.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  From the corner reveal. Referto SOPM 20-30-02 as an accepted procedure. (a) - - Finish Remove 1

Into two parts 1 65B11751-601 or 65B11751-605 Corner Reveal Cut 2 radius both cut edges and blend to get a 125 microinch or smoother surface roughness. Refer to SOPM 20-10-03 as an accepted procedure. - 65B11751-601 or 65B11751-605 Corner Reveal Blend 3

All over both halves of the reveal, Intensity 0.006A. Refer to SOPM 20-10-03 as an accepted procedure. - 65B11751-601 or 65B11751-605 Corner Reveal Shot Peen 4

Chemical conversion coating to all surfaces of both halves of the reveal. Refer to SOPM 20-43- 03 as an accepted procedure. - - Finish Apply 5

One coat of BMS 10-11, Type I primer to all surfaces of both halves of the reveal. Refer to SOPM 20-41-02 as an accepted procedure. - - Finish Apply

Part mark. Refer to SOPM 20-50-10 as an accepted procedure. 1 65B11751-7 Upper Portion of Corner Reveal Identify 6

Part mark. Refer to SOPM 20-50-10 as an accepted procedure. 1 65B11751-9 Lower Portion of Corner Reveal Identify 7

Mark each set of reveals with the following: "65B11751-11:Matched set, do not use separately" 1 65B11751-7 Corner Reveal Set Identify 8 1 65B11751-9
(a) If necessary, also make sure that the sharp edge detail has been removed as shown in Figure 12.

**FIGURE 13: REWORK OF A 1-PIECE LEFT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR CORNER REVEAL**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 98 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 14: REWORK OF A 1-PIECE RIGHT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR**  **CORNER REVEAL (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 99 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each affected left side corner reveal. **NOTE:**These rework instructions are only allowed on 65B11751-602 corner reveals which have been confirmed to be machined from 6061-T6 plate, not 356 aluminum castings. See Figure 4 to determine material. All 65B11751-606 corner reveals are machined from 6061-T6 plate.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  From the corner reveal. Referto SOPM 20-30-02 as an accepted procedure. (a) - - Finish Remove 1

Into two parts 1 65B11751-602 or 65B11751-606 Corner Reveal Cut 2 radius both cut edges and blend to get a 125 microinch or smoother surface roughness. Refer to SOPM 20-10-03 as an accepted procedure. - 65B11751-602 or 65B11751-606 Corner Reveal Adjust 3

All over both halves of the reveal, Intensity 0.006A. Refer to SOPM 20-10-03 as an accepted procedure. - 65B11751-602 or 65B11751-606 Corner Reveal Shot Peen 4

Chemical conversion coating to all surfaces of both halves of the reveal. Refer to SOPM 20-43- 03 as an accepted procedure. - - Finish Apply 5

One coat of BMS 10-11, Type I primer to all surfaces of both halves of the reveal. Refer to SOPM 20-41-02 as an accepted procedure. - - Finish Apply

Part mark. Refer to SOPM 20-50-10 as an accepted procedure. 1 65B11751-8 Upper Portion of Corner Reveal Identify 6

Part mark. Refer to SOPM 20-50-10 as an accepted procedure. 1 65B11751-10 Lower Portion of Corner Reveal Identify 7

Mark each set of reveals with the following: "65B11751-12:Matched set, do not use separately" 1 65B11751-8 Corner Reveal Set Identify 8 1 65B11751-10
(a) If necessary, also make sure that the sharp edge detail has been removed as shown in Figure 12.

**FIGURE 14: REWORK OF A 1-PIECE RIGHT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR CORNER REVEAL**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 100 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 15: LOGIC DIAGRAM FOR THE INSPECTION OF MACHINED REVEALS FOR CRACKS AND A**  **SHARP EDGE DETAIL**

**(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 101 of 106 **BOEING SERVICE BULLETIN 747-53-2460 FIGURE 16: LOGIC DIAGRAM FOR THE INSPECTION OF MACHINED REVEALS WITH SHARP EDGE**  **DETAIL REMOVED FOR CRACKS (SHEET 1 OF 1)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 102 of 106 **BOEING SERVICE BULLETIN 747-53-2460**The step number shown below agrees with the numbers shown in the circle symbols in the figure. The QTY number shown below are the number of parts necessary for each airplane.

**FIGURE 17: INSPECTION FOR ONE OR TWO-PIECE CORNER REVEALS (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 103 of 106 **BOEING SERVICE BULLETIN 747-53-2460 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** to identify installed onepiece or two-piece corner reveals. (a) 2
- Corner Reveal Inspect 1

(a) If the separation line exists, a two-piece corner reveal is installed. The separation line should be filled with BMS 5-95 sealant.

**FIGURE 17: INSPECTION FOR ONE OR TWO-PIECE CORNER REVEALS (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 104 of 106 **BOEING SERVICE BULLETIN 747-53-2460**1. Purpose a. Use this procedure to determine if the Corner Reveal is made from a 356-T6 aluminum casting or 6061 aluminum plate with a heat treat of T6 or T651. b. This procedure uses a chemical etch and a 25X minimum visual inspection. 2. Equipment a. Tools (1) Sanding disks or paper - 320, 600, and 1200-grit silicon carbide (2) 25X minimum portable microscope (3) Cotton swabs b. Chemicals WARNING: NITRIC ACID, HYDROCHLORIC ACID, AND HYDROFLUORIC ACID ARE DANGEROUS LIQUIDS. DO NOT BREATHE THEIR VAPORS. DO NOT GET THESE MATERIALS IN EYES, ON SKIN, OR ON CLOTHING (1) Hydrochloric acid (HCl), concentrated (2) Nitric acid (HNO3), concentrated (3) Hydrofluoric acid (HF), 48% concentrated c. Reference Standard (1) A test sample can be made on a scrap piece of 6061-T6 or 6061-T651 material, using the steps given in this procedure. 3. Preparation of Surface for Chemical Etch a. Identify the inspection area on each Corner Reveal. b. Use the 320-grit sandpaper or grinding wheel to remove any visible roughness. Use water as a lubricant and change directions by 90 degrees frequently in a circular motion c. Use the 600-grit sandpaper or grinding wheel to make the surface smooth. Use water as a lubricant and change directions by 90 degrees frequently in a circular motion d. Finish with a 1200-grit sandpaper or grinding wheel repeating the same circular motion. e. Rinse the surface with clean and fresh water. 4. Chemical Etch Preparation

**Appendix A: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION PROCEDURE (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 105 of 106 **BOEING SERVICE BULLETIN 747-53-2460**WARNING: NITRIC ACID, HYDROCHLORIC ACID, AND HYDROFLUORIC ACID ARE DANGEROUS LIQUIDS. DO NOT MIX THESE MATERIALS ON THE AIRPLANES. DO NOT BREATHE THEIR VAPORS, AND DO NOT GET THESE MATERIALS IN EYES, ON SKIN, OR ON CLOTHING. a. Mix the following chemicals to make the Poulton's reagent: (1) 12 parts HCl, concentrated (2) 6 parts HNO3, concentrated (3) 1 part HF, 48% concentrated (4) 1 part water 5. Etch the Surface to Inspected. a. Apply the Poulton's reagent with a cotton swab for 3-6 seconds or until the microstructure has an adequate contrast b. Rinse the surface with clean water to stop the reagent's action c. Wipe the surface dry with a clean dry cloth 6. Inspect the Etched Surface a. Use the 25X portable microscope, to inspect the etched surface. Inspect for the typical appearance of dendrites in cast and solidified materials. Refer to the Boeing Photo Number 02d00901 for the difference between a cast microstructure and a plate microstructure. NOTE: If the microstructure is not clear, it may be necessary to use a polarizing filter or higher magnification

**Appendix A: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION PROCEDURE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 27, 2002 747-53-2460 Revision 2 December 22, 2010 106 of 106 **BOEING SERVICE BULLETIN 747-53-2460**